TWI529061B - Manufacturing method of composite material - Google Patents

Description

Composite material manufacturing method

The present invention relates to a method for manufacturing a composite material, and more particularly to a method for manufacturing a composite material combining a stainless steel material and a fiber prepreg.

In general, the outer casings of electronic devices such as mobile phones, computers, game consoles, and personal digital assistants (PDAs) are highly rigid and are made of metal materials (such as stainless steel, aluminum alloy, and magnesium alloy) to withstand external impact. Damage caused by falling. In recent years, due to the booming development of portable electronic devices, thinning has become a major demand for the selection of housing materials.

In the process, the metal shell mainly made of metal materials is mainly processed by stamping or cold forging. In order to make the structure of the finished product have high strength, it is achieved through the following materials and methods; For the manufacture of materials, the aluminum alloy sheet with sufficient thickness can be stamped and formed by gluing, or the structure can be processed by cold forging, so that the inner and outer structures of the finished product can be simultaneously formed during processing, and then the CNC is used. (Computer Numerical Control) processing and finishing, but the weight of aluminum alloy is lighter than other metal materials. If a certain strength is to be achieved, the thickness of the material required for processing is relatively increased, resulting in the product being not thinned.

When stainless steel is used as the material, since the stainless steel itself has better steel properties, it can be formed by stamping a thinner stainless steel sheet than the aluminum alloy, and then bonding the structure by gluing, but by this method Although the finished product has a certain degree of thinness, the weight of the product is higher than that of other materials due to the high density of the stainless steel itself.

On the other hand, compared with metal, fiber materials (carbon fiber, glass fiber or metal fiber) have the advantages of lighter quality and high strength, and the fiber material can form a decorative grain effect by itself after weaving. Materials are also used in electronic device housings. However, although the application of the fiber material can achieve the effect of thinning and thinning, it is relatively difficult to continue the shaping of the appearance and the combination with other structures. Therefore, the conventional manufacturing method requires not only a high cost but also a production cost. The surface quality of the finished shell cannot be improved. Therefore, under the limited cost and manpower, it is difficult to simultaneously have the rigidity, the thinness, and the beautification of the appearance.

The present invention discloses a method for manufacturing a composite material comprising the steps of: forming a stainless steel sheet into a stainless steel structural member; placing the stainless steel structural member in a female mold; and providing a fibrous material on the surface of the stainless steel structural member away from the female mold And pressing a male mold toward the mother mold to join the fibrous material to the stainless steel structural member.

The present invention further discloses a method for manufacturing a composite material comprising the steps of: forming a stainless steel sheet into a stainless steel structural member; forming a fibrous material into a fibrous structural member; placing the stainless steel structural member in a female mold; The structural member is coated with an adhesive away from the surface of the mother mold; and the fibrous structural member is placed on the stainless steel structural member coated with the adhesive on the surface, so that the fibrous structural member is joined to the stainless steel structural member by an adhesive.

As described above, the composite material manufacturing method of the present invention can form a composite material having high strength by using a stainless steel material and a fiber material under the control of a specific thickness and molding conditions. In addition, the composite material can have the advantages of two materials at the same time, and has the advantages of high rigidity, lightness and thinness, and simplified process on the basis of low cost consideration. In addition, through the manufacturing method of the composite material of the present invention, the optimum experimental conditions can be found for the needs of different products in the selection and combination of different materials, so that the composite material formed by applying the manufacturing method of the present invention can be widely used. use.

On the other hand, the manufacturing method of the composite material of the present invention can also be separately processed by using different kinds of adhesives together with the two materials, and the molding time of the overall composite material can be shortened and the amount of the composite material can be effectively increased by precisely controlling the bonding time and strength of the adhesive. Productivity.

1, 2, 3, 4‧‧‧ composite materials

11, 31‧‧‧ Stainless steel sheet

11a, 21a, 31a, 41a‧‧‧ stainless steel structural parts

12, 32‧‧‧ fiber materials

12a, 22a, 32a, 42a‧‧‧ fiber structural parts

221a‧‧‧Fiber structure

43‧‧‧Internal components

F‧‧‧Female mold

M‧‧‧Male mold

S‧‧‧ adhesive

S11~S17, S31~S39‧‧‧ steps

1A is a flow chart showing the steps of a method for manufacturing a composite material according to a first embodiment of the present invention.

1B to 1D are schematic views showing the continuous manufacturing of the composite material of FIG. 1A.

Figure 1E is a side elevational view of a composite formed using the method of making the composite of Figure 1A.

Figure 1F is a partial exploded view of the composite of Figure 1E.

2A is a side elevational view of a different aspect of the composite material of the first embodiment of the present invention.

2B is a partial exploded view of the composite of FIG. 2A.

3A is a flow chart showing the steps of a method for manufacturing a composite material according to a second embodiment of the present invention.

3B to 3E are schematic views showing the continuous manufacturing of the composite material of FIG. 3A.

Figure 3F is a side elevational view of a composite formed using the method of making the composite of Figure 3A.

Figure 4 is a side elevational view of a different aspect of the composite of the first embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method of manufacturing a composite material according to a preferred embodiment of the present invention will be described with reference to the accompanying drawings, wherein the same elements will be described with the same reference numerals.

The manufacturing method of a composite material according to the first embodiment of the present invention is as shown in FIG. 1A. The preparation method of the composite material comprises the following steps: processing a stainless steel sheet into a stainless steel structural member (S11); The piece is placed in a mother mold (S13); a fiber material is provided on the surface of the stainless steel structural member away from the mother mold (S15); a male mold is pressed toward the mother mold to join the fiber material to the stainless steel structural member (S17) ).

In the description of each step, please refer to the continuous manufacturing schematic diagram of the composite material shown in FIG. 1B to FIG. 1D in order to understand the technical content of the present invention. In step S11, a stainless steel sheet is first formed into a stainless steel structural member. Wherein, the above-mentioned molding method can be understood, for example, but not limited to, stamping, cold forging, hot forging, casting or other persons having the ordinary knowledge in the technical field of the present invention, and details are not described herein. In addition, in the present embodiment, the stainless steel sheet 11 has a U-shaped structure. However, in the practical application, the stainless steel sheet is formed according to the shape of the device or structure to be actually matched, and the present invention does not limit.

In step S13, the stainless steel structural member is placed in a cavity of a mother mold. Wherein, the size of the cavity is designed to match the size of the stainless steel structural member 11a, which is not limited by the present case. Referring to FIG. 1C, after the stainless steel structural member 11a is placed, step S15 provides a fibrous material 12 on the surface of the stainless steel structural member 11a away from the female mold, in detail, The fibrous material 12 is not subjected to any molding processing, so that it cannot directly contact the surface of the stainless steel structural member 11a. In this embodiment, the thickness ratio of the stainless steel structural member 11a to the fibrous material 12 ranges from 1:4 to 2:3, and the preferred thickness ratio is 3:7. The resulting composite can be optimally balanced in strength and weight.

After the two materials are placed, step S17 presses a male mold toward the mother mold to join the fiber material to the stainless steel structural member. In detail, the configuration of the male mold M is designed according to the structure in which the fibrous material is to be formed, and is not limited by the present invention. Through the press-fitting of the male mold M, the fibrous material 12 can be brought into contact with and joined to the stainless steel structural member 11a by its own viscous property and the pressure applied by the mold while being molded.

In practical applications, an adhesive may be additionally disposed between the stainless steel structural member and the fibrous material to enhance the combined effect of the two, but the embodiment is not limited thereto.

The fiber material 12 described in this embodiment is exemplified by a carbon fiber prepreg, and the fiber material 12 is pre-woven. In practical applications, the fiber material may also be pre-impregnated glass fiber, organic fiber or aramid. Fibers, metal fibers or combinations thereof are not limited herein. In addition, the prepreg treatment of the fiber material is understood and applied by those skilled in the art to which the present invention pertains, and details are not described herein.

In this embodiment, after the step S17 is completed, the mold accommodating the stainless steel structural member 11a and the fiber material 12 is placed in a chamber (see not shown) whose environment condition is controlled, and is closed. The chamber is evacuated, such as but not limited to, a vacuum pressure within the chamber of up to 10 ² Pa. Wherein, the above environmental conditions include controlling the vacuum degree of the cavity, heating, filling gas, or a combination thereof. In addition, it should be noted that the "vacuum" step carried out by the Department is not limited to completely removing the air from the forming mould, but covers the small errors allowed by the manufacturing defects, a few special conditions, or the theory. . By vacuuming the cavity, pressure is directly applied to the mold to promote the forming effect of the mold contents.

Then, after the cavity is evacuated, the cavity is further heated. In the present embodiment, the heating temperature is between 140 and 170 degrees. By pressurizing and heating the cavity, the fiber material 12 can be thermoformed into a fiber structural member 12a, and the stainless steel structural member 11a and the fiber structure can be further formed. Piece 12a fits closer.

According to the above description, in the present embodiment, the temperature curve of the stainless steel is first calculated, and the stress parameters are analyzed, and then the material selection, structural design, and angle adjustment of the mold are performed. The stress problem that may be caused by the material of the second material can effectively overcome the deformation problem caused by the heating of the different materials through the design of the mold and the environmental conditions of the cavity, thereby further improving the precision of the formed composite material and between the materials. Fit.

In addition, the manufacturing method of the composite material of the present embodiment can improve the efficiency of the overall fabrication by eliminating the need to pre-form the two materials, and on the other hand, accurately analyzing the stress parameters of the material, and controlling the configuration and cavity of the mold. The environmental conditions of the body can overcome the deformation problem of using composite materials in the past to form a composite material. Since the manufacturing method of the present embodiment can achieve the combination of the stainless steel and the fiber prepreg without using an adhesive, the problem of deformation or poor fit due to the medium between the composite materials can be eliminated.

1E is a side view of a composite material formed by the method for fabricating the composite material of FIG. 1A, and FIG. 1F is a partial exploded view of the composite material of FIG. 1E. Please refer to FIG. 1E and FIG. The composite material 1 formed by the method has a tightly fitting stainless steel structural member 11a and a fibrous structural member 12a. In the present embodiment, the fibrous structural member 12a has a single layer structure, and the fiber structural form of the fibrous structural member 12a is a single In other embodiments, the fiber structure 12a of the single-layer structure may have different fiber alignments, and the present invention is not limited thereto. It should be noted that the fiber material 12 forming the fiber structural member 12a has a fiber alignment system substantially the same as that of the fiber structural member 12a, and will not be described herein.

As described above, the use of a one-way fiber prepreg material can provide a better strength of the composite material 1, so that the composite material 1 has a uniform and uniform fiber distribution when viewed as a whole, and the material has high rigidity and high strength. That is, through the uniform distribution of the unidirectional fiber texture configuration, the overall mechanical strength can have a uniform performance, such as thermal expansion properties, to make the composite material 1 of the present invention suitable for use in equipment having uniform surface material requirements. In practical applications, the fiber material may also be selected from materials having different fiber orientations, and the present invention is not limited thereto.

2A is a side view showing a different aspect of a composite material according to a first embodiment of the present invention, and FIG. 2B is a partial exploded view of the composite material of FIG. 2A. Please refer to FIG. 2A and FIG. 2B simultaneously. In this embodiment, composite The material 2 has the structure and features of the foregoing embodiment, but the fiber structural member 22a is a three-layer structure, that is, the composite material 2 comprises a stainless steel structural member 21a and a three-fiber structural layer 221a.

In the present embodiment, the fiber structural member 22a having the three fiber structure layer 221a Having different fiber orientations, in detail, the fiber structure layers 221a of the adjacent two layers respectively have different fiber alignments, wherein the three fiber structure layers 221a may be composed of the same fiber material or different materials. However, when the composite material 2 is to be viewed as a whole, the combination of the layers has a fiber grain perpendicular to the projection direction to achieve high rigidity and high strength. The strength of the composite material 2 can be increased by the arrangement of the fiber structural members 22a of the multi-layer structure. However, the number of the fiber structure layers can be increased as appropriate depending on the use requirements.

In addition, it should be particularly noted that although the fiber structural member 22a of the present embodiment has the three-fiber structural layer 221a, the thickness ratio of the stainless steel structural member 21a to the fibrous structural member 22a is still in the range of 1: A preferred thickness ratio between 3 and 2:3 is 3:7.

3A is a flow chart showing the steps of a method for manufacturing a composite material according to a second embodiment of the present invention, and FIG. 3B to FIG. 3E are schematic diagrams showing continuous manufacturing of the composite material of FIG. 3A. Referring to FIG. 3A to FIG. 3E, In this embodiment, the manufacturing method of the composite material 3 comprises the steps of: forming a stainless steel sheet into a stainless steel structural member (S31); processing a fiber material into a fiber structural member (S33); placing the stainless steel structural member In a mother mold (S35); coating an adhesive (S37) on the surface of the stainless steel structural member away from the mother mold; placing the fibrous structural member on the stainless steel structural member coated with the adhesive on the surface, so that the fibrous structural member is Then, it is joined to the stainless steel structural member (S39).

The manufacturing method of the embodiment has the same steps and operation methods as those of the foregoing embodiment, but the manufacturing method of the embodiment is that the fiber material is formed into a fiber structural member in advance, and then the stainless steel structural member and the fiber structural member are transmitted through an adhesive. Engaging, the following will specifically explain how to implement the method of operation of the present embodiment. However, it is also to be noted that the contents of the following embodiments are merely for convenience of description and are not intended to limit the present invention.

In the present embodiment, a stainless steel sheet 31 and a fiber material 32 are first formed into a stainless steel structural member 31a and a fibrous structural member 32a (as shown in FIGS. 3B and 3C), wherein the stainless steel structural member 31a is formed. The molding method can be, for example, but not limited to, stamping, cold forging, hot forging or casting, and the fiber material 32 can be formed into the fiber structural member 32a by pressurization or heating, but the processing method of the above two materials is Those skilled in the art can understand and apply the same, and no further details are provided herein.

In step S35, the formed stainless steel structural member 31a is placed in a mother mold F (as shown in FIG. 3D), and the stainless steel structural member 31a is away from the mother mold F. The surface is coated with an adhesive S. In the present embodiment, AB glue is used as an adhesive, wherein the selected AB adhesive is determined according to the material properties and stress conditions of the stainless steel structural member 31a and the connected 32a. Precisely controlling the time and strength of the adhesive S bonding, and more preferably, since the bonding time and strength can be controlled, the molding time of the overall composite material is shortened, and the efficiency of mass production is effectively improved. However, the type of the adhesive S is not limited by the present invention, and an epoxy resin or a phenolic resin may be used in practical applications, and the present invention is not limited thereto.

Next, after the application of the adhesive S is completed, the step S39 places the fibrous structural member 32a on the stainless steel structural member 31a of the surface coating adhesive S (as shown in FIG. 3E), so that the fibrous structural member 32a is adhered by the adhesive. S is attached to the stainless steel structural member 31a. More preferably, in order to further improve the bonding effect between the stainless steel structural member 31a and the fiber structural member 32a, a male mold (not shown) may be pressed toward the female mold F after the fibrous structural member 32a is placed on the stainless steel structural member 31a. This is not a restriction.

In the present embodiment, the thickness ratio of the stainless steel structural member 31a to the fibrous structural member 32a is in the range of 3:7. By setting the ratio, the manufactured composite material 3 can be optimally matched in strength and weight. balance.

After the above steps are completed, next, as in the foregoing embodiment, the mother mold F including the stainless steel structural member 31a and the fibrous structural member 32a is placed in a cavity for vacuuming and heating. The detailed step process is detailed in the foregoing embodiment, and details are not described herein again. In particular, in the present embodiment, the temperature of the heating chamber is within 120 degrees, and the optimum temperature is 80 degrees. However, the heating temperature is selected according to the type of the selected adhesive, which is not limited by the present invention. condition. After the heating is completed, the composite material 3 as shown in Fig. 3F is obtained.

As described above, the manufacturing method of the present embodiment selectively controls the bonding time of the 31a and the fiber structural member 32a on the stainless steel structural member through the selection of the type of the adhesive and the heating temperature suitable for the flow and curing of the adhesive. Intensity, in addition, similar to the previous embodiment, the present embodiment also overcomes the stress problem that may be generated by the two materials through the material selection, structural design, and angle adjustment of the mold, and is controlled by the mold design and the environmental conditions of the cavity. Effectively overcome the deformation problem caused by the combination of different materials, further improve the precision of the formed composite material 3 and the fit between the materials, thereby overcoming the combination of materials of different materials in different thickness combinations. The stress problem.

Figure 4 is a side view of a different aspect of a composite material of the first embodiment of the present invention In the present embodiment, the composite material 4 has the structure and features of the composite material 1 of the foregoing embodiment, but further includes two inner members 43. The two inner members 43 are respectively disposed on the inner side of the fiber structural member 42a, that is, when the composite material 4 is viewed as a whole, the stainless steel structural member 41a, the fibrous structural member 42a and the two inner members 43 are sequentially included from the outside to the inside, wherein The inner member 43 of the embodiment is made of an aluminum-magnesium alloy to strengthen the strength of the integral composite material 4. However, the materials and installation positions selected for the inner member are not limited by the present invention, and the device or structure for the overall matching application is viewed. Strength requirements are more designed.

On the other hand, the manufacturing method of the composite material of the present invention can also be separately processed by using different kinds of adhesives together with the two materials, and the molding time of the overall composite material can be shortened and the amount of the composite material can be effectively increased by precisely controlling the bonding time and strength of the adhesive. Productivity.

The above is intended to be illustrative only and not limiting. Any equivalent modifications or changes made to the spirit and scope of this case shall be included in the scope of the appended patent application.

S11~S17‧‧‧Steps

Claims (6)

A method of manufacturing a composite material, comprising the steps of: forming a stainless steel sheet into a stainless steel structural member, the stainless steel structural member comprising a first surface and a second surface opposite the first surface; the stainless steel structural member Placed in a female mold, the first surface of the stainless steel structural member contacts the female mold; a fibrous material is provided on the second surface of the stainless steel structural member away from the female mold, the fibrous material does not contact the stainless steel structure The second surface of the piece; and pressing a male mold toward the master mold to join the fiber material to the stainless steel structural member. The manufacturing method according to claim 1, wherein the fiber material is a single layer structure or a multilayer structure. The manufacturing method of claim 2, wherein the fiber material of the single layer structure or the multilayer structure has a different fiber orientation. The manufacturing method of claim 3, wherein the fibrous materials of the adjacent two layers of the multilayer structure respectively have different fiber orientations. The manufacturing method of claim 1, wherein the material of the fiber material comprises carbon fiber, glass fiber, aramid fiber, metal fiber, organic fiber, or a combination thereof. The manufacturing method of claim 1, wherein the ratio of the thickness of the stainless steel structural member to the fibrous material ranges from 1:4 to 2:3.